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Model Curriculum Aircraft Powerplant Technician
(Aerospace Welder)
SECTOR: AEROSPACE AND AVIATION SUB-SECTOR: MAINTENANCE REPAIR & OVERHAULING OCCUPATION: BASE MAINTENANCE
REF ID: AAS/Q2001, V 2.0 NSQF LEVEL: 4
Aircraft Powerplant Technician (Aerospace Welder)
Aircraft Powerplant Technician (Aerospace Welder)
TABLE OF CONTENTS
1. Curriculum 1 2. Trainer Prerequisites 11 3. Annexure: Assessment Criteria 12
Aircraft Powerplant Technician (Aerospace Welder) 1
Aircraft Powerplant Technician (Aerospace Welder) CURRICULUM / SYLLABUS
This program is aimed at training candidates for the job of a “Aircraft Powerplant Technician
(Aerospace Welder)”, in the “Aerospace and Aviation” Sector/Industry and aims at building the
following key competencies amongst the learner
Program Name Aircraft Powerplant Technician (Aerospace Welder)
Qualification Pack Name & Reference ID.
AAS/Q2001
Version No. 1.0 Version Update Date 15 – 03 - 2017
Pre-requisites to Training Class XII ( Science St )
Training Outcomes
After completing this programme, participants will be able to;
Responsibly support aircraft engine assembly and disassembly.
Carry out various welding activities and repair of engine hot/cold sections for all types of aircrafts
Carry out various welding activities/ repair structural components for all types of aircrafts
Carry out various welding activities/ repair of mechanical components for all types of aircrafts
Perform welding in joining various types of metallic frames in aero structures using welding and flame spray coatings.
Perform welding in joining various types of metallic frames in aircraft components using welding and flame spray coatings,
Acquire basic communication skills and good inter-personal skills.
Achieve excellent written communication
Aircraft Powerplant Technician (Aerospace Welder) 2
This course encompasses 6 out of 6 Compulsory National Occupational Standards (NOS) of “Aircraft Powerplant Technician (Aerospace Welder)” Qualification Pack and 1 out of 1 Optional NOS issued by “Aerospace and Aviation Sector Skill Council (AASSC)”.
Compulsory NOS :
Sr.
No. Module Key Learning Outcomes Equipment Required
1 Follow safety and security procedures Theory Duration (hh:mm) 25:00 Practical Duration (hh:mm) 23:00 Corresponding NOS Code AAS/N0502
Candidates will be able to;
comprehend the organisation’s safety and security policies and procedures
comprehend the regulatory guidelines on safe conduct of operations and maintenance of conditions to thwart any acts of unlawful interference
report any identified breaches of safety, and security policies and procedures to the designated person
coordinate with other resources at the workplace (within and outside the organization) to achieve safe and secure environment
identify and mitigate any safety and security hazards like illness, accidents, fires or acts of unlawful interference if it falls within the limits of individual’s authority
report any hazards outside the individual’s authority to the relevant person in line with organisational procedures and regulatory guidelines
follow organisation’s emergency procedures for accidents, fires or acts of unlawful interference
identify and recommend opportunities for improving health, safety, and security to the designated person
complete all health and safety records are updates and procedures well defined
White/Black board, Markers, computer and projector, trainer’s guide, student handbook, Charts regarding health & hygiene, fire-fighting, first aid, chart of prohibited items,
2 Understand the process of aero engine assembly Theory Duration (hh:mm) 36:00 Practical Duration (hh:mm) 54:00 Corresponding NOS Code AAS/N2001
Candidates will be able to;
understand all types of drawings, sketches and work instructions at the beginning of the assembly/disassembly
understand of geometric dimensions and tolerances
understand the rigs, gauges, standard tools, torque wrenches etc.
understand the basics of aero engine and its parts
understand the various materials, parts and consumables used during assembly/disassembly process
understand the criticality of sub-assemblies of an aero engine
understand the right assembly/disassembly methodology
White/Black board/ Chart paper, Markers/Computer and projector, trainer’s guide, student handbook,
Aircraft Powerplant Technician (Aerospace Welder) 3
Sr.
No. Module Key Learning Outcomes Equipment Required
and various process parameters like torque application, fitting tolerances, bolting and fastening as mentioned in the work instruction/organisation
maintenance manuals understand 5 S related to the work
area
while understanding the drawings and sketches,he/she must ensure that the observed problems are highlighted to concerned supervisor
understand the changes which may happen from time to time in assembly/disassembly process based on the approved engine configuration
red flagging of the deviations during the assembly of engine and raising it to concerned supervisor/Quality Inspectors
3 Assembly/disassembly of aero-engine Theory Duration (hh:mm) 36:00 Practical Duration (hh:mm) 55:00 Corresponding NOS Code AAS/N2002
Candidates will be able to;
receive the modules at the workshop area and perform visual inspection of the modules to identify defects
receive the documentation received with the modules to ensure that all relevant details are filled in the documents as per regulatory/organisational policies and procedures
install the modules on the dis-assembly rig and perform dis-assembly of the modules into piece parts
visually inspect the disassembled piece parts and record the defects observed on the piece parts to ascertain if the defects are within acceptable limits to certify airworthiness of the piece parts
tag the piece parts with the appropriate tags and ensure all relevant information is filled as per regulatory/organisation policy and procedures
dispatch the piece parts to the relevant component shops for inspection and repair as deemed necessary
To be competent, the user/individual on the job must be able to:
receive the components and piece parts from the component shops and perform visual inspection to ensure no defects on the received parts
if any defects found, ensure that the defects are within the airworthiness
White/Black board, Markers, computer and projector, trainer’s guide, student handbook,
Aircraft Powerplant Technician (Aerospace Welder) 4
Sr.
No. Module Key Learning Outcomes Equipment Required
limits for module assembly
inspect and verify the airworthiness tags issued by the component shops and ensure that the tags are in line with regulatory/organisational policies and procedures
install the components and piece parts on the module assembly rig
perform assembly of the module
visually inspect the module post assembly to ensure that there are no defects on the module beyond the airworthiness requirements
issue the documentation and relevant tags for the module and dispatch the module for final engine assembly
4 Perform aero-engine module disassembly/assembly Theory Duration (hh:mm) 35:00 Practical Duration (hh:mm) 56:00 Corresponding NOS Code AAS/N2003
Candidates will be able to;
perform visual inspection of the bare assembled engine and record the visual findings on the engine
perform fuel and oil draining procedure on the engine prior to disassembly as per the procedures detailed in the job cards/manufacturer manuals/organisation maintenance manuals
remove the engine accessories installed on the engine cases as per the procedures detailed in the job cards/manfacturer manuals/organisation maintenance manuals
perform disassembly of the engine into its modules as per manufacturer manuals and organisation maintenance manuals
ensure blanking is performed on all required areas to prevent an foreign object entering the modules, accessories and LRU's
perform visual inspection of the modules and record the visual findings on the modules
tag the modules with the relevant information as required under regulatory/organisational policies and procedures
dispatch the modules to the appropriate module shops for further disassembly
dispatch the accessories and other LRU's to the respective component shops for testing and repair with appropriate tags
To be competent, the user/individual
White/Black board/ Chart paper, Markers/Computer and projector, trainer’s guide, student handbook,
Aircraft Powerplant Technician (Aerospace Welder) 5
Sr.
No. Module Key Learning Outcomes Equipment Required
on the job must be able to:
receive the modules from the respective modular shops and perform visual inspection on the modules to certify airworthiness of the modules
inspect the documentation received along with the modules to ensure completeness of the documentation in respect to airworthiness requirements set forth by regulator/organisational policy and procedures
assemble the modules in sequence as detailed in the job card/manufacturer manuals/organisation maintenance manuals
visually inspect the assembled modules to ensure no damage has occurred during assembly.
If any damage found, inspect and verify if the damage is acceptable within the airworthiness limits for engine operations
receive engine accessories and LRU's from the component shops and inspect and verify that the accessories and LRU's are airworthy to be installed on the engine
inspect the documentation received along with the modules to ensure completeness of the documentation in respect to airworthiness requirements set forth by regulator/organisational policy and procedures
install the accessories and LRU's in sequence as detailed in the job card/manufacturer manuals/organisation maintenance manuals
visually inspect the installed accessories and LRU's to ensure no damage has occurred during installation.
If any damage found, inspect and verify if the damage is acceptable within the airworthiness limits for engine operations
dispatch the assembled engine to the engine test cell
Aircraft Powerplant Technician (Aerospace Welder) 6
Sr.
No. Module Key Learning Outcomes Equipment Required
5 Prevention of FOD during engine assembly/disassembly Theory Duration (hh:mm) 16:00 Practical Duration (hh:mm) 16:00 Corresponding NOS Code ASC/N2004
Candidates will be able to;
ensure the availability of blanking, cover etc. at the work place
ensure that no FOD is available near the assembly/disassembly area
ensure proper availability of tools, fixtures and parts
ensure proper accounting of material and tools used during assembly/disassembly
ensure all the open cavities are properly blanked/ covered after the completion of work
White/Black board, Markers, computer and projector, trainer’s guide, student handbook,
6 Maintain 5S at the work premises Theory Duration (hh:mm) 09:00 Practical Duration (hh:mm) 23:00 Corresponding NOS Code ASC/N0021
Candidates will be able to;
follow the sorting process and check that the tools, fixtures & jigs that are lying on workstations are the ones in use and un- necessary items are not cluttering the workbenches or work surfaces.
ensure segregation of waste in hazardous/ non Hazardous waste as per the sorting work instructions
follow the technique of waste disposal and waste storage in the proper bins as per SOP
segregate the items which are labeled as red tag items for the process area and keep them in the correct places
sort the tools/ equipment/ fasteners/ spare parts as per specifications/ utility into proper trays, cabinets, lockers as mentioned in the 5S guidelines/ work instructions
ensure that areas of material storage areas are not overflowing
properly stack the various types of boxes and containers as per the size/ utility to avoid any fall of items/ breakage and also enable easy sorting when required
return the extra material and tools to the designated sections and make sure that no additional material/ tool is lying near the work area
follow the floor markings/ area markings used for demarcating the various sections in the plant as per the prescribed instructions and standards
follow the proper labeling mechanism of instruments/ boxes/ containers and maintaining reference files/ documents with the codes and the lists
check that the items in the respective
White/Black board, Markers, computer and projector, trainer’s guide, student handbook,
Aircraft Powerplant Technician (Aerospace Welder) 7
Sr.
No. Module Key Learning Outcomes Equipment Required
areas have been identified as broken or damaged
follow the given instructions and check for labeling of fluids, oils, lubricants, solvents, chemicals etc. and proper storage of the same to avoid spillage, leakage, fire etc.
make sure that all material and tools are stored in the designated places and in the manner indicated in the 5S instructions
check whether safety glasses are clean and in good condition
keep all outside surfaces of recycling containers are clean
ensure that the area has floors swept, machinery clean and generally clean. In case of cleaning, ensure that proper displays are maintained on the floor which indicate potential safety hazards
check whether all hoses, cabling & wires are clean, in good condition and clamped to avoid any mishap or mix up
ensure workbenches and work surfaces are clean and in good condition
follow the cleaning schedule for the lighting system to ensure proper illumination
store the cleaning material and equipment in the correct location and in good condition
ensure self-cleanliness - clean uniform, clean shoes, clean gloves, clean helmets, personal hygiene
follow the daily cleaning standards and schedules to create a clean working environment
attend all training programs for employees on 5S
support the team during the audit of 5 S
participate actively in employee work groups on 5S and encourage team members for active participation
follow the guidelines for What to do and What not to do to build sustainability in 5S as mentioned in the 5S check lists/ work instructions
Compulsory NOS: Total Duration (hh:mm) 384:00 Theory Duration (hh:mm) 157:00 Practical Duration (hh:mm)
Unique equipment used;
Cut-out model of a typical aero engine
Ground Power Unit (GPU)
Fire extinguisher
Aircraft engine hoists
Aircraft Powerplant Technician (Aerospace Welder) 8
Sr.
No. Module Key Learning Outcomes Equipment Required
227:00 Slings for engine
Video/2D or 3D software based audio-visual training package
Common & special tool kits
Common & special gauges and testers
Common & special cranes
Fork lift, special high lift equipment
personal protective equipment (PPE) (consisting of safety jacket, safety goggles, ear plugs, gloves, safety shoes & safety helmet)
Optional NOS : OPTIONS (Optional to choose any or all or none) OPTION 1: Performing aerospace welding operations
7 Performing aerospace welding operations Total Duration (hh:mm) 192:00 Theory Duration (hh:mm) 81:00 Practical Duration (hh:mm) 111:00 Corresponding NOS Code AAS/N0831
Candidates will be able to;
ensure wearing of Personnel Protective Equipment (PPE) that suits the task such as flame-resistant aprons, safety helmet & hand shields, ear plugs, footwear, safety goggles etc.
comply with organisations Occupational Health & Safety (OHS) standards
ensure that work area around the welding transformer, gas discharge unit, flux wire are clean as mentioned in the work instruction / Standard Operating Procedure (SOP) of organisation
ensure that the welding work area is not around explosives or ignitable material and adequate ventilation is available for exhaust of fumes and gases
check for correctness of power, coolant and operating parts of the machine
escalate any queries to the supervisor
ensure that the required welding material (electrodes, flux wire etc) is issued from the stores
setup welding equipment as per selected welding process or approved Welding Procedure Specification (WPS) and Procedure Qualification Records (PQR)
ensure work piece / test piece are clean from burrs
prepare the edge of work piece / test piece as per the approved drawing specification and welding procedures
White/Black board, Markers, computer and projector, trainer’s guide, student handbook,
Aircraft Powerplant Technician (Aerospace Welder) 9
Sr.
No. Module Key Learning Outcomes Equipment Required
ensure appropriate clamps, jigs and fixtures are available to hold the work piece / test piece to be welded
select appropriate wire / electrode as per engineering drawings, type of welding joints or approved WPS & PQR
select appropriate gas, pressure, amperage and voltage as per approved WPS & PQR
perform the required welding process / technique on a test coupon as per approved WPS and PQR in the presence of supervisor, client or under supervision of third party approver
get the test coupon approval for welding positions from supervisor, client or by third party approver
assist supervisor in maintaining a log book with name, approved certificate no., approved welding position etc.
select appropriate wire / electrode as per engineering drawings, type of welding joints or approved WPS & PQR
select appropriate gas, pressure, amperage and voltage as per approved WPS & PQR
register the work piece / section to be welded to the shop supervisor
understand the fabrication tolerances, root gap, hot pass margins as per the welding specification and approved WPS & PQR for type of weld joint
perform tag welding to the work piece and obtain approval from supervisor
perform full weld as per WPS & PQR and avoid over welding
finish the surface by filing, brushing etc.
inform supervisor about completion and perform self-check of the finished output and send it for the next process as per instructions
Unique equipment used;
Gas cylinder
Safety gagets (gloves, apron, goggles, nose mask & ear plugs)
Welding helmets
TIG welding machine, with foot pedal
Special Tool Kit
Mechanical tool box
Welding material (Inconel & SS321)
Fillet
Aircraft Powerplant Technician (Aerospace Welder) 10
Sr.
No. Module Key Learning Outcomes Equipment Required
Power Stabilizer
Grand Total Duration Minimum Duration for the QP= 384 hrs Theory: 157 hrs Practical: 227 hrs Maximum Duration for the QP= 576 hrs Theory: 238 hrs Practical: 338 hrs
Grand Total Course Duration (Minimum): 384 Hours, 0 Minutes
Grand Total Course Duration (Maximum): 576 Hours, 0 Minutes
This syllabus/ curriculum has been approved by Aerospace and Aviation Sector Skill Council (AASSC)
Aircraft Powerplant Technician (Aerospace Welder) 11
Trainer Prerequisites for Job role: “Aircraft Powerplant Technician (Aerospace Welder)” mapped to Qualification Pack: “AAS/Q2001”
Sl.
No. Area Details
1 Description To deliver accredited training service, mapping to the curriculum detailed above, in accordance with the Qualification Pack “AAS/Q2001”.
2 Personal Attributes
Aptitude for conducting training, and pre/ post work to ensure competent, employable candidates at the end of the training. Strong communication skills, interpersonal skills, ability to work as part of a team; a passion for quality and for developing others; well- organised and focused, eager to learn and keep oneself updated with the latest in the mentioned field.
3 Minimum Educational Qualifications
Diploma
4a Domain Certification
Statutory Certificate from Aerospace and Aviation Sector Skill Council (AASSC) for Job Role: “Aircraft Powerplant Technician (Aerospace Welder)” mapped to QP: “AAS/Q2001”. Minimum accepted score for domain certification will be 80%.
4b Platform Certification
Recommended that the Trainer is certified for the job role “Trainer” mapped to the Qualification Pack : “MEP/Q 0102”. Minimum accepted percentage as per respective SSC guidelines is 80%.
5 Experience 2-3 years of experience
Aircraft Powerplant Technician (Aerospace Welder) 12
Annexure : Assessment Criteria
Job Role Aircraft Powerplant Technician
Qualification Pack AAS/Q2001
Sector Skill Council Aerospace and Aviation Sector Skill Council
Sl. No. Guidelines for Assessment
1
Criteria for assessment for each Qualification Pack will be created by the Sector Skill Council. Each Performance Criteria (PC) will be assigned marks proportional to its importance in NOS. SSC will also lay down proportion of marks for Theory and Skills Practical for each PC.
2 The assessment for the theory part will be based on knowledge bank of questions created by the SSC.
3 Assessment will be conducted for all compulsory NOS, and where applicable, on the selected elective/option NOS/set of NOS.
4 Individual assessment agencies will create unique question papers for theory part for each candidate at each examination/training center (as per assessment criteria below).
5 Individual assessment agencies will create unique evaluations for skill practical for every student at each examination/training center based on this criterion.
6 To pass the Qualification Pack , every trainee should score a minimum of 70% of aggregate marks to successfully clear the assessment.
7 In case of unsuccessful completion, the trainee may seek reassessment on the Qualification Pack.
Compulsory NOS Total Marks: 670
Marks Allocation
Assessment outcomes Assessment Criteria for outcomes Total
Marks Out of
Theory Skills
Practical
1. AAS/N0502 Follow safety and security procedures
PC 1. comply with the organisation’s safety and security policies and procedures
100
10 5 5
PC 2. comply with the regulatory guidelines on safe conduct of operations and maintenance of conditions to thwart any acts of unlawful interference
10 5 5
PC 3. report any identification breaches of safety, and security policies and procedures to the designated person
10 5 5
PC 4. coordinate with other resource at the workplace (within and outside the organisation) to achieve safe and secure environment
20 10 10
PC 5. identify and mitigate any safety and security hazards like illness, accidents, fires or acts of unlawful interference if ti falls within the limit of individual’s authority
10 5 5
PC 6. report any hazards outside the individual’s authority to the relevant person in line with organisational procedures and regulatory guidelines
20 10 10
Aircraft Powerplant Technician (Aerospace Welder) 13
PC 7. follow organisation’s emergency procedures for accidents, fires or acts of unlawful interference
5 2 3
PC 8. identify and recommend opportunities for improving health, safety, and security to the designated person
10 8 2
PC 9. complete all health and safety records are updates and procedures well defined
5 2 3
Total 100 52 48
2. AAS/N2001 Understand the process of aero-engine assembly/disassembly
PC1. understand all types of drawings, sketches and work instructions at the beginning of the assembly
100
10 4 6
PC2. understand of geometric dimensions and tolerances
10 4 6
PC3. understand the rigs, gauges, standard tools, torque wrenches etc.
10 4 6
PC4. understand the basics of aero engine and its parts
10 4 6
PC5. understand the various materials, parts and consumables used during assembly process
10 4 6
PC6. understand the criticality of sub-assemblies during assembly of engine
10 4 6
PC7. understand the right assembly methodology and various assembling process parameters like torque application, fitting tolerances, bolting and fastening as mentioned work instruction/SOP manual
10 4 6
PC8. understand 5 S related to the work area 5 2 3
PC9. while understanding the drawings and sketches, must ensure the observed problems are highlighted to concerned supervisor
5 2 3
PC10. understand the changes which may happen from time to time in assembly process based on the approved engine configuration
10 4 6
PC11. red flagging of the deviations during the assembly of engine and raising it to concerned supervisor/Quality Inspectors
10 4 6
Total 100 40 60
Marks Allocation
Assessment outcomes Assessment Criteria for outcomes Total
Marks Out of
Theory Skills
Practical
3. AAS/N2002 Assembly/disassembly of aero-engine
PC1. perform visual inspection of the bare assembled engine and record the visual findings on the engine
100
5 2 3
PC2. perform fuel and oil draining procedure on the engine prior to disassembly as per the procedures detailed in the job cards/manufacturer manuals/organisation maintenance manuals
5 2 3
Aircraft Powerplant Technician (Aerospace Welder) 14
PC3. remove the engine accessories installed on the engine cases as per the procedures detailed in the job cards/manfacturer manuals/organisation maintenance manuals
5 2 3
PC4. perform disassembly of the engine into its modules as per manufacturer manuals and organisation maintenance manuals
5 2 3
PC5. ensure blanking is performed on all required areas to prevent an foreign object entering the modules, accessories and LRU's
5 2 3
PC6. perform visual inspection of the modules and record the visual findings on the modules
5 2 3
PC7. tag the modules with the relevant information as required under regulatory/organisational policies and procedures
5 2 3
PC8. dispatch the modules to the appropriate module shops for further disassembly
5 2 3
PC9. dispatch the accessories and other LRU's to the respective component shops for testing and repair with appropriate tags
5 2 3
PC10. receive the modules from the respective modular shops and perform visual inspection on the modules to certify airworthiness of the modules
5 2 3
PC11. inspect the documentation received along with the modules to ensure completeness of the documentation in respect to airworthiness requirements set forth by regulator/organisational policy and procedures
5 2 3
PC12. assemble the modules in sequence as detailed in the job card/manufacturer manuals/organisation maintenance manuals
5 2 3
PC13. visually inspect the assembled modules to ensure no damage has occurred during assembly.
5 2 3
PC14. inspect and verify if any damage found is acceptable within the airworthiness limits for engine operations
5 2 3
PC15. receive engine acessories and LRU's from the component shops and inspect and verify that the accessories and LRU's are airworthy to be installed on the engine
5 2 3
PC16. inspect the documentation received along with the modules to ensure completeness of the documentation in respect to airworthiness requirements set forth by regulator/organisational policy and procedures
5 2 3
PC17. install the accessories and LRU's in sequence as detailed in the job card/manufacturer manuals/organisation maintenance manuals
5 2 3
Aircraft Powerplant Technician (Aerospace Welder) 15
PC18. visually inspect the installed accessories and LRU's to ensure no damage has occurred during installation.
5 2 3
PC19. If any damage found, inspect and verify if the damage is acceptable within the airworthiness limits for engine operations
5 2 3
PC20. dispatch the assembled engine to the engine test cell
5 2 3
Total 100 40 60
Marks Allocation
Assessment outcomes Assessment Criteria for outcomes Total
Marks Out of
Theory Skills
Practical
4. AAS/N2003 Perform aero-engine module disassembly/assembly
PC1. receive the modules at the workshop area and perform visual inspection of the modules to identify defects
100
8 3 5
PC2. receive the documentation received with the modules to ensure that all relevant details are filled in the documents as per regulatory/organisational policies and procedures
8 3 5
PC3. install the modules on the disassembly rig and perform diassembly of the modules into piece parts
8 3 5
PC4. visually inspect the disassembled piece parts and record the defects observed on the piece parts to ascertain if the defects are within acceptable limits to certify airworthiness of the piece parts
8 3 5
PC5. tag the piece parts with the appropriate tags and ensure all relevant information is filled as per regulatory/organisation policy and procedures
8 3 5
PC6. dispatch the piece parts to the relevant component shops for inspection and repair as deemed necessary
8 3 5
PC7. receive the components and piece parts from the component shops and perform visual inspection to ensure no defects on the received parts
8 3 5
PC8. ensure that defects, if any , are within the airworthiness limits for module assembly
8 3 5
PC9. inspect and verify the airworthiness tags issued by the component shops and ensure that the tags are in line with regulatory/organisational policies and procedures
8 3 5
PC10. install the components and piece parts on the module assembly rig
7 3 4
PC11. perform assembly of the module 7 3 4
PC12. visually inspect the module post assembly to ensure that there are no defects on the
7 3 4
Aircraft Powerplant Technician (Aerospace Welder) 16
module beyond the airworthiness requirements
PC13. issue the documentation and relavent tags for the module and dispatch the module for final engine assembly
7 3 4
Total 100 39 61
Assessment outcomes Assessment Criteria for outcomes Total
Marks Out of
Theory Skills
Practical
5. AAS/N2004 Prevent FOD during engine assembly/disassembly
PC1. ensure the availability of blanking, cover etc. at the work place
100
20 10 10
PC2. ensure that no FOD is available near the assembly/disassembly area
20 10 10
PC3. ensure proper availability of tools, fixtures and parts
20 10 10
PC4. ensure proper accounting of material and tools used during assembly/diassembly
20 10 10
PC5. ensure all the open cavities are properly blanked/ covered after the completion of work
20 10 10
Total 100 50 50
6. ASC/N0021 Maintain 5s at the work premises
PC1. follow the sorting process and check that the tools, fixtures and jigs that are lying on workstations are the ones in use and un-necessary items are not cluttering the workbenches or work surfaces
170
30 10 20
PC2. ensure segregation of waste in hazardous/ non Hazardous waste as per the sorting work instructions
PC3. follow the technique of waste disposal and waste storage in the proper bins as per SOP
PC4. segregate the items which are labeled as red tag items for the process area and keep them in the correct places
PC5. sort the tools/ equipment/ fasteners/ spare parts as per specifications/ utility into proper trays, cabinets, lockers as mentioned in the 5S guidelines/ work instructions
PC6. ensure that areas of material storage areas are not overflowing
30 10 20
PC7. properly stack the various types of boxes and containers as per the size/ utility to avoid any fall of items/ breakage and also enable easy sorting when required
PC8. return the extra material and tools to the designated sections and make sure that no additional material/ tool is lying near the work area
PC9. follow the floor markings/ area markings used for demarcating the various sections
Aircraft Powerplant Technician (Aerospace Welder) 17
in the plant as per the prescribed instructions and standards
PC10. follow the proper labeling mechanism of instruments/ boxes/ containers and maintaining reference files/ documents with the codes and the lists
30 10 20
PC11. check that the items in the respective areas have been identified as broken or damaged
PC12. follow the given instructions and check for labeling of fluids, oils. lubricants, solvents, chemicals etc. and proper storage of the same to avoid spillage, leakage, fire etc.
PC13. make sure that all material and tools are stored in the designated places and in the manner indicated in the 5S instructions
PC14. check whether safety glasses are clean and in good condition
50 10 40
PC15. keep all outside surfaces of recycling containers are clean
PC16. ensure that the area has floors swept, machinery clean and generally clean. In case of cleaning, ensure that proper displays are maintained on the floor which indicate potential safety hazards
PC17. check whether all hoses, cabling & wires are clean, in good condition and clamped to avoid any mishap or mix up
PC18. ensure workbenches and work surfaces are clean and in good condition
PC19. follow the cleaning schedule for the lighting system to ensure proper illumination
PC20. store the cleaning material and equipment in the correct location and in good condition
PC21. ensure self-cleanliness - clean uniform, clean shoes, clean gloves, clean helmets, personal hygiene
PC22. follow the daily cleaning standards and schedules to create a clean working environment
30 10 20
PC23. attend all training programs for employees on 5 S
PC24. support the team during the audit of 5S
PC25. participate actively in employee work groups on 5S and encourage team members for active participation
PC26. follow the guidelines for What to do and What not to do to build sustainability in 5S as mentioned in the 5S check lists/ work instructions
Total 170 50 120
Aircraft Powerplant Technician (Aerospace Welder) 18
Options
Option 1: Aerospace Welder Total Marks: 100
Marks Allocation
Assessment outcomes
Assessment Criteria for outcomes Total Marks
Out of Theory Skills Practical
1.1. AAS/ N0831 Perform aerospace welding operations
PC1. wear Personnel Protective Equipment
(PPE) that suits the task such as flame-
resistant aprons, safety helmet and hand
shields, ear plugs, footwears, safety
goggles etc
100
8 4 4
PC2. comply with organisations Occupational
Health and Safety (OHS) standards 8 4 4
PC3. ensure that work area around the welding
transformer, gas discharge unit, flux wire
are clean as mentioned in the work
instruction / Standard Operating
Procedure (SOP) of organisation
5 2 3
PC4. ensure that the welding work area is not
around explosives or ignitable material and
adequate ventilation is available for
exhaust of fumes and gases
5 2 3
PC5. check for correctness of power,coolant
and operating parts of the machine 5 2 3
PC6. escalate any queries to the supervisor 5 2 3
PC7. ensure that the required welding material
(electrodes, flux wire etc) is issued from
the stores
5 2 3
PC8. setup welding equipment as per selected
welding process or approved Welding
Procedure Specification (WPS) and
Procedure Qualification Records (PQR)
5 2 3
PC9. ensure work piece / test piece are clean
from burrs 5 2 3
PC10. prepare the edge of work piece / test
piece as per the approved drawing
specification and welding procedures
5 2 3
PC11. ensure appropriate clamps, jigs and
fixtures are available to hold the work
piece / test piece to be welded
5 2 3
PC12. select appropriate wire / electrode as per
engineering drawings, type of welding
joints or approved WPS and PQR
5 2 3
PC13. select appropriate gas, pressure, amperage
and voltage as per approved WPS and PQR 5 2 3
PC14. perform the required welding process /
technique on a test coupon as per
approved WPS and PQR in the presence of
5
2
3
Aircraft Powerplant Technician (Aerospace Welder) 19
supervisor, client or under supervision of
third party approver
PC15. get the test coupon approval for welding positions from supervisor, client or by third party approver
PC16. assist supervisor in maintaining a log book with name, approved certificate number approved welding position etc.,
5 2 3
PC17. select appropriate wire / electrode as per engineering drawings, type of welding joints or approved WPS and PQR
5 2 3
PC18. select appropriate gas, pressure, amperage and voltage as per approved WPS and PQR
5 2 3
PC19. register the workpiece / section to be welded to the shop supervisor
5 2 3
PC20. understand the fabrication tolerances, root gap, hot pass margins as per the welding specification and approved WPS and PQR for type of weld joint
4 2 2
PC21. perform tag welding to the work piece and obtain approval from supervisor
4 2 2
PC22. perform full weld as per WPS and PQR and avoid over welding
4 2 2
PC23. finish the surface by filing, brushing etc., 4 2 2
PC24. inform supervisor about completion and perform self check of the finished output and send it for the next process as per instructions
4 2 2
Total 100 42 58
Grand Total (Marks) 770 313 457
Percentage Weightage (%) 41 59